Power tool and method for wireless communication

ABSTRACT

A power tool having multiple wireless communication states and a method of wirelessly communicating by a power tool. The power tool includes a motor, a battery pack interface that selectively receives a battery pack, a backup power source, and a wireless communication controller coupled to the backup power source and the battery pack interface. The wireless communication controller operates in a connectable state when coupled to a battery pack and transmits tool operational data to the external device and receives tool configuration data from the external device. The wireless communication controller operates in an advertisement state when the wireless communication controller is coupled to and powered by the backup power source. In the advertisement state, the wireless communication controller is configured to transmit the unique tool identifier. The external device may also display an indication of the communication state of the power tool.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/668,488, filed Aug. 3, 2017, which is a continuation of U.S. patentapplication Ser. No. 15/146,535, filed May 4, 2016, now U.S. Pat. No.9,756,402, which claims priority to U.S. Provisional Patent ApplicationNo. 62/190,295, filed on Jul 9, 2015, and U.S. Provisional PatentApplication No. 62/156,856, filed on May 4, 2015, the entire contents ofwhich are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to power tools that communicate wirelesslywith an external device.

SUMMARY

In one embodiment, a power tool is provided having multiple wirelesscommunication states. The power tool includes a motor, a battery packinterface that selectively receives a battery pack, and a backup powersource. The power tool further includes a wireless communicationcontroller coupled to the backup power source and the battery packinterface. The wireless communication controller includes a wirelesstransceiver, a processor, and a unique tool identifier. Additionally,the wireless communication controller is configured to operate in aconnectable state when the wireless communication controller is coupledto and powered by the battery pack. In the connectable state, thewireless communication controller is configured to form a wirelesscommunication link with an external device and to one or more oftransmit tool operational data to the external device and receive toolconfiguration data from the external device. The wireless communicationcontroller is further configured to operate in an advertisement statewhen the wireless communication controller is coupled to and powered bythe backup power source. In the advertisement state, the wirelesscommunication controller is configured to transmit an advertisementmessage including the unique tool identifier.

In another embodiment, a method of wirelessly communicating by a powertool is provided. The method includes, the method determining, by awireless communication controller of the power tool, that the batterypack interface is connected to a battery pack. The wirelesscommunication controller enters a connectable state for wirelesscommunication based on determining that the battery pack interface isconnected to the battery pack. The method further includes forming awireless communication link with an external device in the connectablestate, and communicating, over the wireless communication link, to oneor more of transmit tool operational data and receive tool configurationdata from the external device. The method also includes determining, bythe wireless communication controller, that a battery pack interface isdisconnected from the battery pack. The wireless communicationcontroller enters an advertisement state for wireless communicationbased on determining that the battery pack interface is disconnectedfrom the battery pack. The wireless communication controller furthertransmits an advertisement message including a unique tool identifier ofthe power tool when in the advertisement state.

In another embodiment, a power tool having multiple wirelesscommunication states is provided. The power tool includes a motor, abattery pack interface that selectively receives a battery pack and abackup power source. The power tool further includes a real-time clock,a wireless communication controller, and a controller. The real-timeclock is coupled to the backup power source and configured to maintain acurrent time. The wireless communication controller is coupled to thebackup power source and the battery pack interface; includes a wirelesstransceiver, a processor, and a unique tool identifier; and isconfigured to receive a lock out time. The controller is configured toreceive the lock out time from the wireless communication controller andthe current time. The controller is further configured to lock the powertool upon determining that the current time exceeds the lock out time.

In one embodiment, the invention provides a cordless power toolincluding a drive device, a handle portion, a motor portion (e.g., anupper main body of a housing), a backup battery, and a real time clock.The handle portion of the power tool includes a foot of the power tool.The power tool is configured to receive a removable battery pack. Thebackup battery powers the real time clock even when the removablebattery pack is detached from the tool.

In some embodiments, the backup battery is positioned adjacent aBluetooth module, and the Bluetooth module is positioned at the foot ofthe tool.

In some embodiments, the backup battery is positioned within a pocketinside the power tool and is easily accessible for backup batteryreplacement when applicable. The pocket does not interfere with theattachable power tool battery pack and does not interfere withadditional accessories (e.g., belt clip tool holder and bit holder). Thepocket is positioned in an area of the power tool such that the backupbattery is not damaged when the tool is dropped and impacts onto a hardsurface.

In another embodiment, the invention provides a method for identifyingwhen different power tools are within a particular area (e.g., a generalvicinity), and what tools, specifically, are present. The method furtherincludes identifying to the user whether the power tool is in aconnectable state or in an inaccessible state based on whether a batterypack is currently attached to the power tool.

In one embodiment, the invention provides a power tool including a drivedevice for performing a task, a motor coupled to the drive device andconfigured to drive the drive device, a wireless communicationcontroller having a real-time clock, a backup power source, a receivingportion configured to receive a main power source, and a controller. Thecontroller is coupled to the motor, the wireless communicationcontroller, and the main power source. The controller is configured tocontrol the operation of the motor.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a communication system according to one embodiment ofthe invention.

FIG. 2 illustrates an external device of the communication system.

FIG. 3 illustrates a power tool of the communication system.

FIG. 4 illustrates selection switches of the power tool.

FIG. 5 illustrates a battery pack receiving portion of the power tool.

FIGS. 6A-B illustrate a schematic diagram of the power tool.

FIG. 7 is a flowchart illustrating a method of changing settingsassociated with a security feature.

FIG. 8 illustrates an exemplary screenshot of a user interface of anexternal device of the communication system.

FIG. 9 illustrates an exemplary home screen for a power tool.

FIGS. 10A-D illustrate exemplary security screens for the power tool.

FIG. 11 illustrates an exemplary scheduled lock screen for the powertool.

FIGS. 12A-E illustrate a backup power source of the power tool.

FIG. 13 illustrates a schematic diagram of alternative locations for thebackup power source.

FIG. 14 illustrates a method of operating the power tool.

FIG. 15 illustrates a method of wirelessly communicating by the powertool

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limited. The use of“including,” “comprising” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. The terms “mounted,” “connected” and“coupled” are used broadly and encompass both direct and indirectmounting, connecting and coupling. Further, “connected” and “coupled”are not restricted to physical or mechanical connections or couplings,and can include electrical connections or couplings, whether direct orindirect.

It should be noted that a plurality of hardware and software baseddevices, as well as a plurality of different structural components maybe utilized to implement the invention. Furthermore, and as described insubsequent paragraphs, the specific configurations illustrated in thedrawings are intended to exemplify embodiments of the invention and thatother alternative configurations are possible. The terms “processor”“central processing unit” and “CPU” are interchangeable unless otherwisestated. Where the terms “processor” or “central processing unit” or“CPU” are used as identifying a unit performing specific functions, itshould be understood that, unless otherwise stated, those functions canbe carried out by a single processor, or multiple processors arranged inany form, including parallel processors, serial processors, tandemprocessors or cloud processing/cloud computing configurations.

FIG. 1 illustrates a communication system 100. The communication system100 includes power tool devices 104 a, 104 b, and 104 c, eachgenerically referred to as the power tool 104, and an external device108. The power tool 104 and the external device 108 can communicatewirelessly while they are within a communication range of each other.The power tool 104 may communicate power tool status, power tooloperation statistics, power tool identification, stored power tool usageinformation, power tool maintenance data, and the like. Therefore, usingthe external device 108, a user can access stored power tool usage orpower tool maintenance data. With this tool data, a user can determinehow the power tool 104 has been used, whether maintenance is recommendedor has been performed in the past, and identify malfunctioningcomponents or other reasons for certain performance issues. The externaldevice 108 can also transmit data to the power tool 104 for power toolconfiguration, firmware updates, or to send commands (e.g., turn on awork light, lock power tool 104, and the like). The external device 108also allows a user to set operational parameters, safety parameters,select tool modes, and the like for the power tool 104.

The external device 108 may be, for example, a laptop computer, a tabletcomputer, a smartphone, a cellphone, or another electronic devicecapable of communicating wirelessly with the power tool 104 andproviding a user interface. The external device 108 provides the userinterface and allows a user to access and interact with toolinformation. The external device 108 can receive user inputs todetermine operational parameters, enable or disable features, and thelike. The user interface of the external device 108 provides aneasy-to-use interface for the user to control and customize operation ofthe power tool 104.

As shown in FIG. 2, the external device 108 includes an external deviceprocessor 114, a short-range transceiver 118, a network communicationinterface 122, a touch display 126, and a memory 130. The externaldevice processor 114 is coupled to the short-range transceiver 118, thenetwork communication interface 122, the touch display 126, and thememory 130. The short-range transceiver 118, which may include or iscoupled to an antenna (not shown), is configured to communicate with acompatible transceiver within the power tool 104. The short-rangetransceiver 118 can also communicate with other electronic devices. Thenetwork communication interface 122 communicates with a network toenable communication with the remote server 112. The networkcommunication interface 122 may include circuitry that enables theexternal device 108 to communicate with the network. In someembodiments, the network may be an Internet network, a cellular network,another network, or a combination thereof.

The memory 130 of the external device 108 also stores core applicationsoftware 134. The external device processor 114 accesses and executesthe core application software 134 in memory 130 to launch a controlapplication. After the external device 108 launches the controlapplication, the external device 108 receives inputs from the user(e.g., via the touch display 126). In response to the inputs, theexternal device 108 communicates with the power tool 104 to updatesoftware in the power tool 104. Through these updates, a user is able todefine the operation of the power tool 104. In some embodiments, theexternal device 108 also communicates with the remote server 112 toprovide information regarding the operation of the power tool 104 andthe like.

The external device 108 includes the short-range transceiver 118, whichis compatible with a wireless communication interface or module of thepower tool 104. The communication interface of the external device 108may include a wireless communication controller (e.g., a Bluetooth®module), or a similar component. The external device 108, therefore,grants the user access to data related to the power tool 104, andprovides a user interface such that the user can interact with thecontroller of the power tool 104.

In addition, the external device 108 can also share the informationobtained from the power tool 104 with the remote server 112. The remoteserver 112 may be used to store the data obtained from the externaldevice 108, provide additional functionality and services to the user,or a combination thereof. In one embodiment, storing the information onthe remote server 112 allows a user to access the information from aplurality of different devices and locations (e.g., a remotely locateddesktop computer). In another embodiment, the remote server 112 maycollect information from various users regarding their power tooldevices and provide statistics or statistical measures to the user basedon information obtained from the different power tools. For example, theremote server 112 may provide statistics regarding the experiencedefficiency of the power tool 104, typical usage of the power tool 104,and other relevant characteristics and/or measures of the power tool104. In some embodiments, the power tool 104 may be configured tocommunicate directly with the server 112 through an additional wirelessinterface or with the same wireless interface that the power tool 104uses to communicate with the external device 108.

The power tool 104 is configured to perform one or more specific tasks(e.g., drilling, cutting, fastening, pressing, lubricant application,sanding, heating, grinding, bending, forming, impacting, polishing,lighting, etc.). For example, an impact wrench is associated with thetask of generating a rotational output (e.g., to drive a bit), while areciprocating saw is associated with the task of generating areciprocating output motion (e.g., for pushing and pulling a saw blade).The task(s) associated with a particular tool may also be referred to asthe primary function(s) of the tool.

Although the power tool 104 illustrated and described herein is animpact wrench, embodiments of the invention similarly apply to and canbe used in conjunction with a variety of power tools (e.g., a powerdrill, a hammer drill, a pipe cutter, a sander, a nailer, a grease gun,etc.). As shown in FIG. 3, the power tool 104 includes an upper mainbody 202, a handle 204, a battery pack receiving portion 206, selectionswitch 208, an output drive device or mechanism 210, and a trigger 212(or other actuator). The housing of the power tool 104 (e.g., the mainbody 202 and the handle 204) are composed of a durable and light-weightplastic material. The drive device 210 is composed of a metal (e.g.,steel). The drive device 210 on the power tool 104 is a socket. However,each power tool 104 may have a different drive device 210 specificallydesigned for the task associated with the power tool 104. For example,the drive device 210 for a power drill may include a bit driver, whilethe drive device 210 for a pipe cutter may include a blade. Theselection switch 208 is configured to select the speed and/or torquemode for the power tool 104. For instance, different modes stored on thepower tool 104 may have different speed or torque levels, and pressingthe selection switch 208 cycles between the different modes of the powertool 104. For embodiments in which the power tool 104 is different thanthe impact wrench 104, the different modes may be related to settingsfor other parameters such as, for example, crimping pressures forcrimpers. FIG. 4 illustrates a more detailed view of the selectionswitch 208.

FIG. 5 illustrates the battery pack receiving portion 206. The batterypack receiving portion 206 is configured to receive and couple to abattery pack 215 (for example, power tool device 104 b illustrated inFIG. 1) that provides power to the power tool 104. The battery pack 215may also be referred to as a main power source 215. The battery packreceiving portion 206 includes a connecting structure to engage amechanism that secures the battery pack 215 and a terminal block 270 toelectrically connect the battery pack 215 to the power tool 104. In theillustrated embodiment, the connecting structure includes guides 207 andnotches 209 (see FIGS. 12B and 12C) to secure the battery pack to thepower tool 104. The terminal block 270 includes terminals 275 that makecontact with terminals of the battery pack 215 when the battery pack 215is coupled to the battery pack receiving portion 206. Such contactallows for the power tool 104 to be electrically connected to thebattery pack 215.

FIG. 6A illustrates a block diagram of some embodiments of the powertool 104, such as those with motors (e.g., the impact driver 104 a ofFIG. 1). As shown in FIG. 6A, the power tool 104 also includes a motor214. The motor 214 actuates the drive device 210 and allows the drivedevice 210 to perform the particular task. The primary power source(e.g., the battery pack) 215 couples to the power tool 104 and provideselectrical power to energize the motor 214. The motor 214 is energizedbased on the position of the trigger 212. When the trigger 212 isdepressed the motor 214 is energized, and when the trigger 212 isreleased, the motor 214 is de-energized. In the illustrated embodiment,the trigger 212 extends partially down a length of the handle 204;however, in other embodiments the trigger 212 extends down the entirelength of the handle 204 or may be positioned elsewhere on the powertool 104. The trigger 212 is moveably coupled to the handle 204 suchthat the trigger 212 moves with respect to the tool housing. The trigger212 is coupled to a push rod, which is engageable with a trigger switch213 (see FIG. 6A). The trigger 212 moves in a first direction towardsthe handle 204 when the trigger 212 is depressed by the user. Thetrigger 212 is biased (e.g., with a spring) such that it moves in asecond direction away from the handle 204, when the trigger 212 isreleased by the user. When the trigger 212 is depressed by the user, thepush rod activates the trigger switch 213, and when the trigger 212 isreleased by the user, the trigger switch 213 is deactivated. In otherembodiments, the trigger switch 213 is an electrical trigger switch 213,and the trigger 212 is coupled to the electrical trigger switch 213. Insuch embodiments, the trigger switch 213 may include, for example, atransistor. Additionally, for such electronic embodiments, the trigger212 may not include a push rod to activate the mechanical switch.Rather, the electrical trigger switch 213 may be activated by, forexample, a position sensor (e.g., a Hall-Effect sensor) that relaysinformation about the relative position of the trigger 212 to theelectrical trigger switch 213.

As shown in FIG. 6A, the power tool 104 also includes a switchingnetwork 216, sensors 218, indicators 220, a battery pack interface 222,a power input unit 224, a controller 226, a wireless communicationcontroller 250, a backup power source 252, and a real-time clock (RTC)260. In some embodiments, the RTC 260 is part of the wirelesscommunication controller 250 as shown in FIG. 6B. Additionally, in someembodiments, the wireless communication controller 250 may be combinedto be a component of the controller 226. The battery pack interface 222is coupled to the controller 226 and couples to the battery pack 215.The battery pack interface 222 includes a combination of mechanical(e.g., the battery pack receiving portion 206) and electrical componentsconfigured to and operable for interfacing (e.g., mechanically,electrically, and communicatively connecting) the power tool 104 with abattery pack 215. The battery pack interface 222 is coupled to the powerinput unit 224. The battery pack interface 222 transmits the powerreceived from the battery pack 215 to the power input unit 224. Thepower input unit 224 includes combinations of active and passivecomponents (e.g., voltage step-down controllers, voltage converters,rectifiers, filters, etc.) to regulate or control the power receivedthrough the battery pack interface 222 and provided to the wirelesscommunication controller 250 and controller 226.

The switching network 216 enables the controller 226 to control theoperation of the motor 214. Generally, when the trigger 212 is depressed(i.e., the trigger switch 213 is closed), electrical current is suppliedfrom the battery pack interface 222 to the motor 214, via the switchingnetwork 216. When the trigger 212 is not depressed, electrical currentis not supplied from the battery pack interface 222 to the motor 214. Insome embodiments, the trigger switch 213 may include sensors to detectthe amount of trigger pull (e.g., released, 20% pull, 50% pull, 75%pull, or fully depressed). In some embodiments, the amount of triggerpull detected by the trigger switch 213 is related to or corresponds toa desired speed of rotation of the motor 214. In other embodiments, theamount of trigger pull detected by the trigger switch 213 is related toor corresponds to a desired torque.

In response to the controller 226 receiving the activation signal fromthe trigger switch 213, the controller 226 activates the switchingnetwork 216 to provide power to the motor 214. The switching network 216controls the amount of current available to the motor 214 and therebycontrols the speed and torque output of the motor 214. The switchingnetwork 216 may include numerous field effect transistors (FETs),bipolar transistors, or other types of electrical switches.

The sensors 218 are coupled to the controller 226 and communicate to thecontroller 226 various signals indicative of different parameters of thepower tool 104 or the motor 214. The sensors 218 include, for example,one or more current sensors, one or more voltage sensors, one or moretemperature sensors, one or more speed sensors, one or more Hall Effectsensors, etc. For example, the speed of the motor 214 can be determinedusing a plurality of Hall Effect sensors to sense the rotationalposition of the motor 214. In some embodiments, the controller 226controls the switching network 216 in response to signals received fromthe sensors 218. For example, if the controller 226 determines that thespeed of the motor 214 is increasing too rapidly based on informationreceived from the sensors 218, the controller 226 may adapt or modifythe active switches or switching sequence within the switching network216 to reduce the speed of the motor 214. Data obtained via the sensors218 may be saved in the controller 226 as tool usage data.

The indicators 220 are also coupled to the controller 226 and receivecontrol signals from the controller 226 to turn on and off or otherwiseconvey information based on different states of the power tool 104. Theindicators 220 include, for example, one or more light-emitting diodes(“LED”), or a display screen. The indicators 220 can be configured todisplay conditions of, or information associated with, the power tool104. For example, the indicators 220 are configured to indicate measuredelectrical characteristics of the power tool 104, the status of thepower tool 104, etc. The indicators 220 may also include elements toconvey information to a user through audible or tactile outputs.

As described above, the controller 226 is electrically and/orcommunicatively connected to a variety of modules or components of thepower tool 104. In some embodiments, the controller 226 includes aplurality of electrical and electronic components that provide power,operational control, and protection to the components and modules withinthe controller 226 and/or power tool 104. For example, the controller226 includes, among other things, a processing unit 230 (e.g., amicroprocessor, a microcontroller, or another suitable programmabledevice), a memory 232, input units 234, and output units 236. Theprocessing unit 230 includes, among other things, a control unit 240, anarithmetic logic unit (“ALU”) 242, and a plurality of registers 244(shown as a group of registers in FIG. 6A). In some embodiments, thecontroller 226 is implemented partially or entirely on a semiconductor(e.g., a field-programmable gate array [“FPGA”] semiconductor) chip,such as a chip developed through a register transfer level (“RTL”)design process.

The memory 232 includes, for example, a program storage area 233 a and adata storage area 233 b. The program storage area 233 a and the datastorage area 233 b can include combinations of different types ofmemory, such as read-only memory (“ROM”), random access memory (“RAM”)(e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.),electrically erasable programmable read-only memory (“EEPROM”), flashmemory, a hard disk, an SD card, or other suitable magnetic, optical,physical, or electronic memory devices. The processing unit 230 isconnected to the memory 232 and executes software instructions that arecapable of being stored in a RAM of the memory 232 (e.g., duringexecution), a ROM of the memory 232 (e.g., on a generally permanentbasis), or another non-transitory computer readable medium such asanother memory or a disc. Software included in the implementation of thepower tool 104 can be stored in the memory 232 of the controller 226.The software includes, for example, firmware, one or more applications,program data, filters, rules, one or more program modules, and otherexecutable instructions. The controller 226 is configured to retrievefrom memory and execute, among other things, instructions related to thecontrol processes and methods described herein. The controller 226 isalso configured to store power tool information on the memory 232. Thepower tool information stored on the memory 232 may include power toolidentification information (e.g., including a unique identifier of thepower tool 104) and also power tool operational information includinginformation regarding the usage of the power tool 104, informationregarding the maintenance of the power tool 104, power tool triggerevent information, and other information relevant to operating ormaintaining the power tool 104. Such power tool information may then beaccessed by a user with the external device 108. In other constructions,the controller 226 includes additional, fewer, or different components.

The wireless communication controller 250 is coupled to the controller226. In the illustrated embodiment, the wireless communicationcontroller 250 is located near the foot of the power tool 104 (see FIG.3) to save space and ensure that the magnetic activity of the motor 214does not affect the wireless communication between the power tool 104and the external device 108. As a particular example, in someembodiments, the wireless communication controller 250 is positionedunder the user interface 261 on the foot of the power tool 104, whichincludes the mode selection switch 208 and an example of the indicators220 (in the form of a mode indicator) in a recess spanning a dividingline of the power tool's clam shell housing. As shown in FIG. 6B, thewireless communication controller 250 includes an antenna and radiotransceiver 254, a memory 256, a processor 258, and a real-time clock(RTC) 260. The antenna and radio transceiver 254 operate together tosend and receive wireless messages to and from an external device 108and the processor 258. The memory 256 can store instructions to beimplemented by the processor 258 and/or may store data related tocommunications between the power tool 104 and the external communicationdevice 108 or the like. The processor 258 for the wireless communicationcontroller 250 controls wireless communications between the power tool104 and the external device 108. For example, the processor 258associated with the wireless communication controller 250 buffersincoming and/or outgoing data, communicates with the controller 226, anddetermines the communication protocol and/or settings to use in wirelesscommunications.

In the illustrated embodiment, the wireless communication controller 250is a Bluetooth® controller. The Bluetooth® controller communicates withthe external device 108 employing the Bluetooth® protocol. Therefore, inthe illustrated embodiment, the external device 108 and the power tool104 are within a communication range (i.e., in proximity) of each otherwhile they exchange data. In other embodiments, the wirelesscommunication controller 250 communicates using other protocols (e.g.,Wi-Fi, cellular protocols, etc.) over a different type of wirelessnetwork. For example, the wireless communication controller 250 may beconfigured to communicate via Wi-Fi through a wide area network such asthe Internet or a local area network, or to communicate through apiconet (e.g., using infrared or NFC communications). The communicationvia the wireless communication controller 250 may be encrypted toprotect the data exchanged between the power tool 104 and the externaldevice 108 (or network) from third parties. In the illustratedembodiment, the wireless communication controller 250 is configured toperiodically broadcast an identification signal, also referred to asidentification information or identification data. The identificationsignal includes identification information for the power tool 104, suchas a unique identifier. The external device 108 identifies the powertool 104 via the identification signal. Additionally or alternatively,the wireless communication controller 250 may be configured to respondto a ping signal from the external device 108. In other words, thewireless communication controller 250 may not periodically broadcast theidentification signal, but rather the wireless communication controller250 may wait for a ping signal from the external device 108 to send theidentification signal.

The wireless communication controller 250 is configured to receive datafrom the power tool controller 226 and relay the information to theexternal device 108 via the antenna and transceiver 254. In a similarmanner, the wireless communication controller 250 is configured toreceive information (e.g., configuration and programming information)from the external device 108 via the antenna and transceiver 254 andrelay the information to the power tool controller 226.

The RTC 260 increments and keeps time independently of the other powertool components. In the illustrated embodiment, the RTC 260 is poweredthrough the wireless communication controller 250 when the wirelesscommunication controller 250 is powered. In some embodiments, however,the RTC 260 is a separate component from the wireless communicationcontroller 250. In such embodiments, the RTC 260 receives power from thebattery pack 215 (e.g., a main or primary power source) when the batterypack 215 is connected to the power tool 104. The RTC 260 receives powerfrom the backup power source 252 (e.g., a coin cell battery, anothertype of battery cell, a capacitor, or another energy storage device)when the battery pack 215 is not connected to the power tool 104.Therefore, the RTC 260 keeps track of time regardless of whether thepower tool 104 is in operation, and regardless of whether the batterypack 215 is connected to the power tool 104. When no power source ispresent (i.e., the battery pack 215 is detached from the power tool 104and the backup power source 252 is removed or depleted), the RTC 260stores the last valid time. When a power source is replaced (i.e., thebattery pack 215 is attached to the power tool 104 and/or the backuppower source 252 is replaced), the RTC 260 uses the stored time as astarting point to resume keeping time.

The starting time for the RTC 260 is set to current Greenwich mean time(GMT) time at the factory at time of manufacture. The time is updated orsynchronized whenever the wireless communication controller 250communicates with the external device 108. Because GMT time isindependent of calendar, seasons, or time schemas, using GMT time allowsthe power tool 104 or the external device 108 to convert from timeindicated by the RTC 260 to localized time for display to the user.

Because the RTC 260 is able to maintain accurate time whether or not thebattery pack 215 is attached to the power tool 104, the RTC 260 isconfigured to time-stamp (i.e., associate a specific time with) theoperational data of the power tool 104. For example, the controller 226can store the operational data when, for example, the power tool 104 isfastening a group of fasteners. The controller 226 then receives anindication of time (e.g., a GMT time) from the RTC 260 or from theprocessor 258 associated with the wireless communication controller 250.The controller 226 proceeds to store the operational data (e.g., thetorque output by the power tool 104, the speed of the motor 214, thenumber of trigger pulls, etc.) with a time-stamp provided based on thereceived time from the RTC 260. The RTC 260 can continuously orperiodically provide an indication of time to the controller 226. Inother embodiments, the controller 226 requests a time signal from theprocessor 258 of the wireless communication controller 250 and waits forthe time signal from the RTC 260.

The RTC 260 also allows the controller 226 to keep track of maintenanceand/or service schedules. For example, maintenance for a particular toolmay be scheduled once every year. The maintenance time or date can bestored in the memory 232 or 256 and the controller 226 or 250periodically compares the time from the RTC 260 to the storedmaintenance time or date and generates an alert when the date/time isreached. The alert can be sent to the external device 108 and/or besignaled via indicators 220.

The RTC 260 also enables the power tool 104 to implement a time-basedlock-out feature. In the time-based lock-out feature, the memory 232 or256 may also store a security date and time information or a timeramount. The controller 226 monitors the time received from the RTC 260and compares the current time from the RTC 260 to the user-specifiedlock-out time stored in the memory 232 or 256. When the current timefrom the RTC 260 exceeds the user-specified lock-out time, thecontroller 226 locks the power tool 104 (e.g., the power tool 104 isdisabled such that driving the motor 214 is prevented). The power tool104, therefore, becomes inoperable. Since the RTC 260 keeps timeindependent of other components in the power tool 104 and independent ofthe operation of the power tool 104, the controller 226 can moreaccurately track when maintenance or service for a particular tool or aparticular part is due and/or when a specified time for a securityfeature is approaching.

The processor 258 of the wireless communication controller 250 switchesbetween operating in a connectable (e.g., full power) state andoperating in an advertisement state. The wireless communicationcontroller 250 operates in the connectable state when the battery pack215 is attached to the power tool 104 and contains sufficient charge topower the wireless communication controller 250 and the controller 226,and to support substantive electronic data communication between thepower tool 104 and the external device 108. When the wirelesscommunication controller 250 operates in the connectable state, wirelesscommunication between the power tool 104 and the external device 108 isenabled. In the connectable state, the wireless communication controller250 obtains and exports tool operational data including tool usage data,maintenance data, mode information, drive device information, and thelike from the power tool 104. The exported operational data is receivedby the external device 108 and can be used by tool users or owners tolog operational data related to a particular power tool 104 or tospecific job activities. The exported and logged operational data canindicate when work was accomplished and that work was accomplished tospecification. The logged operational data can also provide achronological record of work that was performed, track duration of toolusage, and the like. In the connectable state, the wirelesscommunication controller 250 also imports (i.e., receives) configurationdata from the external device 108 into the power tool 104 such as, forexample, operation thresholds, maintenance thresholds, modeconfigurations, programming for the power tool 104, feature information,and the like. The configuration data is provided by the wirelesscommunication controller 250 to the controller 226 over communicationchannel 262, and the processing unit 230 stores the configuration datain the memory 232. The processing unit 230 further accesses theconfiguration data stored in the memory 232 and controls driving of themotor 214 in accordance with the configuration data. For example, theprocessing unit 230 may drive the motor 214 at a particular speed oruntil a particular torque is reached (e.g., as detected by the sensors218), where the particular speed or torque is provided as part of theconfiguration data.

If the battery pack 215 is not connected to the wireless communicationcontroller 250 or if the battery pack 215 is depleted, the wirelesscommunication controller 250 operates in the advertisement state. Whilein the advertisement state, the wireless communication controller 250receives power from the backup power source 252 (e.g., a coin cellbattery, another type of battery cell, a capacitor, or another energystorage device). The backup power source 252 provides sufficient powerfor the wireless communication controller 250 to periodically broadcastan advertisement message, but may not provide sufficient power to allowthe wireless communication controller 250 to engage in further dataexchange with the external device 108, or, such further data exchangewould deplete the backup power source 252 more rapidly than desired. Inother words, the communication capabilities of the power tool 104 arelimited or restricted when the wireless communication controller 250 isin the advertisement state. In some embodiments, when the wirelesscommunication controller 250 operates in the connectable state, thebackup power source 252 does not provide power to the wirelesscommunication controller 250 and battery life of the backup power source252 is therefore extended.

The external device 108 can enable a security feature of the power tool104. In such embodiments, a user enables the security feature throughthe control application executed by the external device 108. Theexternal device 108 then communicates with the wireless communicationcontroller 250 to indicate to the power tool 104 that the user hasenabled the security feature. FIG. 7 illustrates an exemplary method 700for enabling and implementing the security feature. The controlapplication receives user instructions to search for the power tools 104(or power tool devices) that are within the communication range of theexternal device 108 (at block 264). The control application determineswhich power tools 104 are within the communication range based on theadvertisement messages broadcasted by the power tools 104 and receivedby the external device 108.

The external device 108 identifies to the user which power tools 104 arewithin the communication range by displaying a tool icon 268 for eachpower tool within the communication range, as shown in FIG. 8 (at block272). The tool icon 268 includes an icon image and accompanyingidentification text data for each power tool (e.g., Steve's Drill). Theicon image may be a photograph obtained from, for example, themanufacturer that represents the selected power tool 104, and/or theicon image may be a photograph obtained from the user that representsthe power tool 104. The external device 108 also identifies to the userwhether the power tool 104 is in the connectable state or in theadvertisement state (i.e., the status of the power tool 104). Thisidentification by the external device 108 indicates to the user theidentity of power tools 104 that are within the communication range ofthe external device 108, the state of each power tool 104 that is withincommunication range, and whether substantive data exchange can occurbetween each of the power tools 104 and the external device 108.

In some embodiments, the icon 268 representing the power tool 104 on thegraphical user interface of the external device 108 changes based on themode of the power tool 104. For example, in the some embodiments, theicon 268 for the power tool 104 is white on blue when the power tool 104is in the connectable state, and gray on white when the power tool 104is in the advertisement state. Stated another way, the text or iconscorresponding to power tools 104 in the advertisement state may bedisplayed in a grayed-out or faded manner (see, e.g., symbol 269 a)relative to power tools in the connectable state (see, e.g., symbol 269b). In other embodiments, the specific icons 268 corresponding to theconnectable state and to the advertisement state may be different (e.g.,in shape, symbol, or text), rather than merely in color, and the icon268 corresponding to the connectable state is distinguishable from theicon corresponding to the advertisement state. The icons 268 can havedifferent tool colors, background colors, symbols, letters, and the likedepending on the state of the power tool 104 (e.g., connectable state oradvertisement state). The icons 268 can flash, not flash, or flash atdifferent frequency depending on whether the power tool 104 is in theconnectable state or the advertisement state. Additionally, in someembodiments, the external device 108 also displays different icons 268for other states of the power tool 104. For example, if the power tool104 is in operation (i.e., the motor 214 is running or has been runrecently), the external device 108 displays a first icon. If the powertool 104 is in the connectable state but not in operation, the externaldevice 108 displays a second icon. If the power tool 104 is in theadvertisement state and the backup power source 252 holds sufficientpower, the external device 108 displays a third icon. The externaldevice 108 may display a fourth icon if the backup power source 252 islow, and a fifth icon if the tool 104 experiences intermittentcommunication. Additionally, the icon 268 may change corresponding tohow many seconds have passed since the advertisement or communicationwas last received from the power tool 104.

The external device 108 determines the state of the power tool 104 basedon the information it receives from the power tool 104. For example, insome embodiments, when the power tool 104 is in operation, the wirelesscommunication controller 250 sends a corresponding signal to theexternal device 108 indicating that the motor 214 is currentlyoperating. As another example, when the power tool 104 is in theadvertisement state (i.e., the battery pack 215 is detached from thepower tool 104), the wireless communication controller 250 sends acorresponding advertisement message to the external device 108. Theexternal device 108 determines the state of the power tool 104 based onthe received signal and changes the icons 268 according to thedetermined state of the power tool 104.

When the wireless communication controller 250 operates in theadvertisement state, the power tool 104 identifies itself to theexternal device 108, but data exchange between the power tool 104 andthe external device 108 is limited to select information. In otherwords, in the advertisement state, the wireless communication controller250 outputs an advertisement message to the external device 108. Theadvertisement message includes one or more of identification informationregarding the tool identity (e.g., a serial number or other unique toolidentifier), remaining capacity of the backup power source 252, andother limited amount of power tool information (e.g., configurationinformation used by third-party smartphone applications). Theadvertisement message also identifies the product as being from aparticular manufacturer or brand via a global unique identification(GUID) that includes the power tool's specific make, model, and serialnumber. Even when operating in the advertisement state, the externaldevice 108 can identify the power tool 104 and determine that the powertool 104 is within a communication range of the external device 108(e.g., locate the power tool 104) based on the advertisement message,but further data between the external device 108 and the power tool 104is not exchanged. The tool identification also allows for specificidentification of power tools to differentiate between different powertools of the same module.

Based on the displayed list of power tools 104, the user selects aparticular tool 104 to enable the security feature. Returning to FIG. 7,the control application running on the external device 108 receives theuser's selection of the particular power tool 104 (at block 274). Inresponse to receiving the user's selection of the particular power tool104, the control application running on the external device 108 displaysa home screen 276 particular to the selected power tool 104, as shown inFIG. 9 (at block 278). The home screen 276 for the selected power tool104 allows the user to control different aspects of the power tool 104.For example, in the illustrated embodiment, the control applicationenables the user to view, assign, and adjust tool settings to differentpower tool modes. The control application also enables the user tocustomize, assign, and share tool profiles. The control application alsoenables the user to enable and customize lock-out settings for the powertool 104. In particular, a user can select to expand the menu associatedwith the security feature (e.g., “SECURITY FEATURES”) to change and/orupdate the settings associated with the lock-out feature. Returning toFIG. 7, the control application receives the user selection of the“SECURITY FEATURES” option (i.e., the security menu) (at block 280). Inresponse to receiving the user selection of the security menu, thecontrol application displays a security screen 282, as shown in FIG.10A-10D (at block 283).

As shown in FIGS. 10A-B, the security screen 282 includes an on/offindicator 284, a current status indicator 286, and a scheduled lockoption 288. The on/off indicator 284 indicates the general setting forthe security feature. The on/off indicator 284 is movable between an ONposition and an OFF position. As shown in FIG. 10A, when the on/offindicator 284 is in the OFF position, the lock-out feature is disabledand the power tool 104 can operate openly without restrictions from thesecurity feature. When the security feature is disabled, the currentstatus indicator 286 and the scheduled lock option 288 are grayed outand disabled. In other words, the control application disables theuser's ability to change the current security status of the power tool104 and/or set a scheduled lock when the security feature is disabled.In FIG. 10A, to indicate that the current status indicator 286 and thescheduled lock option 288 are disabled, these items are shown inhollowed blocked letters.

If, on the other hand, the on/off indicator 284 is in the ON position,as shown in FIG. 10B, the lock-out feature is enabled and the user canspecify different settings of the security feature. The security screen282 indicates the current security status of the power tool 104 using acurrent status indicator 286. The security feature enables two types ofsecurity control. The first security control is a direct control of thepower tool operation regulated by a current status selector 287. Thesecond security control is regulated by the scheduled lock options 288.The current status selector 287 allows the user to change the currentsecurity status of the power tool 104. For example, the external device108 may receive a user selection via the current status selector 287 toswitch the current status of the power tool 104 between unlocked andlocked. The current status selector 287 shows the opposite option as thecurrent status of the power tool 104. For example, when the currentstatus of the power tool 104 is “locked,” the current status selector287 shows an option to “unlock” the power tool 104. In contrast, whenthe current status of the power tool 104 is “unlocked,” the currentstatus selector 287 shows an option to “lock” the power tool 104. Thecurrent status selector 287 provides a binary option for switching thepower tool 104 between an operable state and a locked-out state.

In the illustrated example of FIG. 10B, the current status of the powertool 104 is “locked.” Therefore, the power tool 104 is restricted in itsoperation and is currently under lock-out (e.g., not enabled tooperate). In some embodiments, the power tool 104 may be under lock-outby providing minimal power to the motor 214 of the power tool 104. Inother embodiments, the power tool 104 may be under lock-out byinhibiting electrical power from reaching the motor 214 of the powertool 104, thereby rendering the power tool 104 inoperable. While thecurrent status of the power tool 104 is “locked,” the scheduled lockoption 288 is grayed out and unavailable for user selection. In FIG.10B, to indicate that the scheduled lock option 288 is not available forselection, it is shown in hollowed blocked letters. On the other hand,the current status selector 287 is shown in solid letters to indicatethat it is enabled and available for selection.

Returning to FIG. 7, when implementing the security feature, the controlapplication determines whether the user changed the current status ofthe power tool 104 (at block 302) using the current status selector 287.If the control application determines that the current status of thepower tool 104 has changed, the control application proceeds to block303 and forwards the updated security settings (e.g., lock or unlock) tothe power tool 104. The control application then proceeds to determinewhether the user has changed settings associated with the scheduled lock(at blocks 304-316). If the control application determines that thecurrent status of the power tool 104 has not changed in block 302, thecontrol application proceeds to determine whether the user has changedsettings associated with the scheduled lock (at blocks 304-316).

For example, as shown in FIG. 10C, the current status of the power tool104 is “unlocked,” as indicated by the current status indicator 286.Therefore, the power tool 104 is operable. When the current status ofthe power tool 104 is “unlocked,” the scheduled lock option 288 isavailable for user selection. In FIG. 10C, to indicate that thescheduled lock option 288 is available for selection, it is shown insolid letters similar to the current status indicator 286.

As shown in FIGS. 10C and 10D, the scheduled lock option 288 includes aschedule lock on/off selector 292, a future lock-out indication 294, andan edit option 296. The schedule lock on/off selector 292 enables anddisables the scheduled lock option 288 accordingly. When the scheduledlock is disabled (i.e., the on/off selector 292 is in the OFF positionas shown in FIG. 10C), the power tool 104 operates according to thecurrent status selector 287. When the schedule lock is enabled, however,(i.e., the on/off selector 292 is in the ON position as shown in FIG.10D) the control application displays the future lock-out indication294. The future lock-out indication 294 indicates to the user a currenttime 298 and an indication 300 of the remaining time before the powertool 104 is under lock-out. In some embodiments, instead of the currenttime 298, the control application displays the defined lock-out time andthe remaining time before the power tool 104 becomes inoperable.Returning to FIG. 7, at block 304, the control application determineswhether the scheduled lock is enabled (at block 304). If the scheduledlock is disabled (e.g., the on/off selector 292 is in the OFF position),the control application waits for additional user input (e.g., pressingof a back or cancel key) and responds accordingly (at block 305). Forexample, the control application may return to a previous block of themethod 700 based on the additional user input.

On the other hand, if the scheduled lock is enabled, the controlapplication determines whether the edit option 296 has been selected (atblock 306). If the control application determines that the edit option296 is not selected, the control application proceeds to block 320 andforwards updated settings to the power tool 104. In some instances(e.g., when the user does not change any security settings), the controlapplication bypasses block 320 and proceeds back to block 283. If thecontrol application receives an indication that the user selected theedit option 296, the control application displays a scheduled lock editscreen 308, as shown in FIG. 11 (at block 312).

The edit option 296 and the edit screen 308 allow the user to change thespecified time before the power tool 104 becomes inoperable due to thesecurity feature. As shown in FIG. 11, the edit screen 308 includeseditable lock fields 309 a-h. Each editable lock field 309 a-h displaysa current setting value and can be changed by the user. For instance,selecting field 309 a causes a drop down calendar to be displayedthrough which the control application can receive a user's dateselection. The other lock fields 309 b-h are similarly updateablethrough user selection and/or direct text entry. As shown on the editscreen 308, the user specifies a period of time (e.g., three hours or 30days), and/or an end (e.g., disable) date (e.g., Jun. 15, 2015), suchthat when the period of time has expired or the specified end date haspassed based on the date/time indicated by the RTC 260, the power tool104 locks out and becomes disabled (i.e., the power tool 104 is renderedinoperable even if a new battery pack 215 is attached). When the userenables the security feature and enters the edit screen 308, the userindicates a period of time or a disable time. As shown in FIG. 11, theuser can select whether to edit the “lock-out time” or the “remainingtime.” In the illustrated embodiment, when the user changes one of thelock-out time or the remaining time, the other option automaticallyupdates to correspond to the same lock-out time. For example, if theuser enters a new lock-out time (e.g., Jun. 15, 2015 at 5:30 P.M.), thecontrol application automatically updates the remaining time. In theillustrated embodiment, the current time is Jun. 13, 2015 1:58 P.M. and,thus, the remaining time shows two days, three hours, and 32 minutes.

A user can alternatively specify a period of time instead of a specificdisable time, by adjusting the remaining time options. Being able tochange the units of the time period also allows a user to have moreflexibility in scheduling. The control application then calculates thedisable date based on the current date and the user specified period oftime. In the illustrated example, the user can identify the remainingtime to be two days, three hours, and 32 minutes. The controlapplication then calculates that the disable time would be Jun. 15, 2015at 5:30 P.M., and updates the displayed lock out time in lock fields 309a and 309 b accordingly. Although the remaining time options in theillustrated embodiment only include days, hours, and minutes, the unitsfor each digit may be changed. For example, the user may change thefirst label from days to weeks. In such an instance, the lock-out timewould be later than Jun. 15, 2015.

Returning to FIG. 7, once the user has made the desired changes to thescheduled lock settings, the control application receives and saves theupdated settings (at block 316). The external device 108 thencommunicates with the power tool 104 to forward the updated settings forthe scheduled lock and/or for the direct lock (at block 320). Inparticular, the external device 108 communicates to the power tool 104whether the power tool 104 is to change from the lock state to theunlock state, from the unlock state to the lock state, and/or whether ascheduled lock has been established for the power tool 104 along withthe scheduled lock settings.

When the wireless communication controller 250 receives data indicatingthat the user enabled the security feature and the specified disabledate, the wireless communication controller 250 (e.g., the processor258) forwards the information to the controller 226 as previouslydescribed with respect to other tool data. The controller 226 updatesstored data to indicate that the security feature has been enabled andthe indicated current state and the disable date (e.g., lock-out time).The controller 226 compares the current day/time from the RTC 260 to thedisable data periodically or upon each trigger pull. Once the controller226 determines that the disable date has been reached, the controller226 ceases to drive the motor 214. The power tool 104 remains enabledwhen the security feature is disabled. Therefore, wireless communicationbetween the power tool 104 and the external device 108 enables toolowners to limit tool usage based on a time. In other embodiments, thesecurity features may disable the power tool 104 based on otherparameters such as, for example, number of trigger pulls, number ofcompleted tasks, number of power on/off switches, and the like. Forexample, the security control screen 282 includes additional fields toreceive user input specifying these other parameters.

Additionally, in some embodiments, the power tool 104 may shut downpermanently when it has not communicated with an external device 108 fora predetermined period of time or after a predetermined number ofunsuccessful attempts to communicate with an external device 108. Forexample, in such embodiments, the external device 108 may provide anacknowledgement message to the power tool 104 to indicate that theexternal device 108 received a message (e.g., an identification signal,an advertisement message, or the like) from the power tool 104. When thepower tool 104 does not receive such an acknowledgement message from theexternal device 108 after a predetermined period of time or after apredetermined number of unsuccessful attempts, the wirelesscommunication controller 250 may control the power tool 104 to enter thelocked state (i.e., disable operation of the motor 214). The power tool104 may remain permanently locked or semi-permanently locked. To exit asemi-permanent lock sate, the power tool 104 may need to be returned toan authorized dealer or the manufacturer for unlocking (e.g., viaproviding to the power tool 104 a particular authorization coderecognizable by the controller 226). In some embodiments, the power tool104 exits the semi-permanent lock state upon establishing acommunication link with the external device 108.

In the illustrated embodiment, the security feature is disabled bydefault (e.g., from the factory) and is then enabled by the user at alater time. When no power source is available (i.e., the battery pack215 and the backup power source 252 are disconnected from the power tool104 or are depleted), the RTC 260 cannot keep time. Therefore, the RTCtime is not incremented and the period of time specified by the userwill be extended because the tool 104 will require a longer time periodto reach the disable time. To operate the power tool 104 again, thebattery pack 215 must be connected to the power tool 104. When a chargedbattery pack 215 is connected to the power tool 104, the RTC 260increments time again, the disable time is reached, and the power tool104 is disabled. Therefore, even if the backup power source 252 isdepleted, the security feature is not disabled. Accordingly, the powertool 104 provides a way to manage and limit the use of the power tool104 and provides a level of tool lock-out and security that can beenabled by the tool owner to decrease or deter theft of power tools.

The backup power source 252 (e.g., a coin cell battery, another type ofbattery cell, a capacitor, or another energy storage device) includes anindependent assembly within the power tool 104 that includes its ownunique printed circuit board (PCB) 323 (see FIGS. 12A-E). The backuppower source 252 provides power to the wireless communication controller250 to enable the wireless communication controller 250 to operate inthe advertisement state. The backup power source 252 also provides powerto the RTC 260 to enable continuous tracking of time. The backup powersource 252 does not provide power to energize the motor 214, drive thedrive device 210, or power the controller 226, and generally only powersthe wireless communication controller 250 and the RTC 260 (e.g., inembodiments in which the RTC 260 is separate from the wirelesscommunication controller 250) when the battery pack 215 is not attachedto the power tool 104. In other embodiments, the backup power source 252also provides power to low-power elements such as, for example, LEDs,and the like. In some embodiments, the wireless communication controller250 includes a voltage sensor 265 (see FIG. 6B) coupled to the backuppower source 252. The wireless communication controller 250 uses thevoltage sensor 265 to determine the state of charge of the backup powersource 252. The wireless communication controller 250 may include thestate of charge of the backup power source 252 in the advertisementmessage to the external device 108. The user can then be alerted whenthe state of charge of the backup power source 252 is low. In otherembodiments, the wireless communication controller 250 only includes thestate of charge of the backup power source 252 in the advertisementmessage when the state-of charge is below a low power threshold.Accordingly, the user can be alerted to charge or replace the backuppower source 252.

As shown in FIGS. 12A-D, the backup power source 252 includes a coincell battery 324 located on the PCB 323. The coin cell battery 324 ismerely exemplary. In some embodiments, the backup power source 252 maybe another type of battery cell, a capacitor, or another energy storagedevice. The coin cell battery 324 is positioned proximate (e.g., near)the wireless communication controller 250 to minimize wiring within thepower tool 104. The coin cell battery 324 provides sufficient power toallow the wireless communication controller 250 to operate in theadvertisement state and broadcast minimal identification information. Inthe illustrated embodiment, the coin cell battery 324 can run forseveral years by allowing the power tool 104 to only “broadcast” or“advertise” once every few seconds when operating the advertisementstate.

In the illustrated embodiment, the coin cell battery 324 is a primary(i.e., non-rechargeable) backup battery. In other embodiments, thebackup power source 252 includes a secondary (rechargeable) backupbattery cell or a capacitor. In such embodiments, the battery pack 215provides charging power to recharge the secondary backup battery cell orthe capacitor. For example, the power input unit 224 may includecharging circuitry to charge the backup power source 252. Therechargeable cell and capacitor may be sized to provide power forseveral days or weeks before needing to recharge.

The backup power source 252 is inserted as a separate assembly insidethe handle 204 of the power tool 104. As shown in FIGS. 12A-E, thebattery pack receiving portion 206 also includes a coin cell slot 328.The coin cell slot 328 is positioned adjacent the connecting structurethat receives the battery pack 215 and is a separate compartment of thetool housing. The foot of the power tool 104 (i.e., the battery packreceiving portion 206) defines a foot print perimeter of the power tool104. The perimeter is defined by the edges A, B, C, D (see FIG. 5) ofthe battery pack receiving portion 206. As shown more clearly on FIG. 5,the coin cell slot 328 is positioned on a lateral side (i.e., side B orD) of the battery pack receiving portion 206. As shown in FIG. 5 andFIG. 12E, the backup power source 252 is secured in place by a removableplastic cover 332. The removable plastic cover 332 is attached to thepower tool housing by two screws 333. The screws can be removed whenreplacement of the battery is needed (e.g., when the voltage of the coincell battery 324 depletes). In some embodiments, the coin cell slot 328is accessible via a sliding or hinged door.

Although in the illustrated embodiment, the coin cell slot 328 ispositioned within the battery pack receiving portion 206, in otherembodiments, the coin cell slot 328 is positioned elsewhere on the powertool 104. For example, FIG. 13 schematically illustrates various otherpositions E, F, G for the coin cell slot 328. For example, position Eshows the coin cell slot 328 being positioned below the selection switch208 at the foot of the power tool 104. Position F shows the coin cellslot 328 at or near a location where the handle 204 and the foot of thepower tool 104 meet. Position G shows the coin cell slot 328 in thehandle 204, and, in particular, in a bottom portion of the housing ofthe handle 204.

Positioning the coin cell slot 328 in the battery pack receiving portion206 has several advantages. For example, because the coin cell slot 328is positioned in the battery pack receiving portion 206, the batterypack 215 is removed before the coin cell battery 324 is replaced,thereby ensuring that the power tool 104 is not in operation while thecoin cell battery 324 is replaced. Additionally, including the coin cellslot 328 in the battery pack receiving portion 206 avoids having theslot 328 straddle the interface of the power tool's right and left clamshell housing portion, which could weaken the structural integrity ofthe housing. Furthermore, by positioning the coin cell slot 328 in thebattery pack receiving portion 206, the manufacturing of the housingremains mostly the same. In other words, since the position of the coincell slot 328 is within an already existing portion of the housing, mostof the portions manufactured to make the housing can remain the same anda limited number of changes to the housing design have to be made. Forexample, as shown more clearly in FIGS. 12B-C, both sides of the housinghave the same profile. By placing the coin cell battery 324 in thebattery pack receiving portion 206, the coin cell battery 324 utilizesspace not previously utilized, keeping the power tool 104 compact andefficient.

The position of the coin cell battery 324 also does not interfere withany of the foot accessories of the power tool 104. For example, on thesame side of the foot that houses the coin cell slot 328, a belt hookmount 336 is provided having three recesses 338 a, 338 b, and 338 c(FIG. 12D) for attachment of a belt hook 340 (see FIG. 13).Additionally, a lanyard is attachable to the belt hook mount 336. In theillustrated embodiment, the power tool 104 includes the belt hook mount336 on both lateral sides, including the lateral side having the coincell slot 328, yet the coin cell slot 328 does not interfere with theattachment of the belt hook 340. Each of the belt hook mounts 336 is aprotrusion from one of the lateral sides of the power tool 104. The belthook 340 including an attachment end with a throughole 341 and twobosses not shown. The throughole 341 aligns with the (threaded) recess338 a, which includes a threaded insert, and the each of the bossesaligns with one of the (alignment) recesses 338 b and 338 c. To securethe belt hook 340 to the belt hook mount 336, a screw is insertedthrough the throughole 341 and into the threaded recess 338 a where thescrew is rotated to fasten the belt hook 340. The recesses 338 a, 338 b,and 338 c of the belt hook mount 336 stop short of, and do not extendinto the, the coin cell slot 328.

In some embodiments, the wireless communication controller 250 resideswith the backup power source 252 in the coin cell slot 328. For example,the PCB 323 may include both terminals for receipt of a power source,such as coin cell battery 324, and the wireless communication controller250. In such embodiments, the communication channel 262 may be in theform of a selectively connectable ribbon cable or other connector thatcouples the PCB 323 (and the components thereon) with the controller226. Accordingly, the PCB 323, including the backup power source 252 andthe wireless communication controller 250, may be part of a modular unitthat is selectively inserted into (or removed from) the power tool 104to selectively provide wireless communication capabilities for the powertool 104. In such embodiments, the wireless communication controller 250may be coupled to the power input 224, as shown in FIG. 6A, through thesame ribbon cable that provides the communication channel 262.Accordingly, the wireless communication controller 250 may be powered bya battery pack coupled to the battery pack interface 222, if present, orthe backup power source 252. A switch on the PCB 323 may be controlledto select between power sources based on the presence or absence ofpower available from the power input 224.

FIG. 14 illustrates a method 1400 of general operation of the power tool104. First, the power tool 104 (e.g., controller 226 or 250) determineswhether there is a power source present (at block 342). If there is apower source present (e.g., the battery pack 215 is connected to thepower tool 104 or the backup power source 252 is available), the RTC 260increments time (at block 344) and saves the latest RTC time (at block348) in case the power source becomes disconnected and/or depleted.Stated another way, at block 348, the controller 226 obtains the RTCtime. The controller 226 then determines whether the user is attemptingto operate the power tool 104 (at block 352). For example, thecontroller 226 may monitor the trigger switch 213 to determine whetherthe user is attempting to operate the power tool 104.

If the user is not attempting to use the power tool 104, the power tool104 remains idle and the method 1400 proceeds back to block 342.However, if the user is attempting to utilize the power tool 104, thecontroller 226 then determines whether the security feature is enabled(at block 356). If the security feature is not enabled, the power tool104 operates normally (at block 360). From block 360, the method 1400may proceed back to block 342 to repeat the method 1400. At block 356,if the security feature is enabled, the controller 226 determineswhether the current status of the power tool 104 is set to “unlock” (atblock 364). If the current status of the power tool 104 is not set to“unlock” (e.g., the status is set to “lock”), the power tool 104 remainsidle and the controller 226 disables normal operation of the power tool104 (at block 368). From block 368, the method 1400 may proceed back toblock 342 to repeat the method 1400.

At block 364, if the current status of the power tool 104 is set to“unlock,” the controller 226 then determines whether the scheduled lockis enabled (at block 372). If the scheduled lock is disabled, the powertool 104 operates normally (at block 360). If the scheduled lock isenabled, the controller 226 determines whether the current RTC timeexceeds the disable time (at block 376). If the current RTC time has notexceeded the disable time (i.e., the lock-out time), the power tool 104operates normally (at block 360). On the other hand, if the RTC timemeets or exceeds the disable time, the power tool 104 is becomes idleand the controller 226 disables normal operation of the power tool 104(at block 368). The power tool 104 remains disabled until the securityfeature is disabled or the disable time is updated to a future time onthe external device 108. As indicated in FIG. 14, from both of blocks360 and 368, the method 1400 may proceed back to block 342 to repeat themethod 1400. Repetition of the method 1400 allows the power tool 104 toreceive updated security features from the external device 108 thatallow the power tool 104 to adjust its security settings and operationsettings.

In some embodiments, blocks 342 and 344 occur independently (i.e.,separate from) the method 1400. In some embodiments, the method 1400further includes a block of obtaining security settings (e.g., inadvance of obtaining the RTC time in block 348). Obtaining securitysettings may occur through receipt, by the controller 226, of securitysettings from the external device 108 as provided in blocks 303 and 320of FIG. 7.

FIG. 15 illustrates a method 1500 of wirelessly communicating by a powertool, such as the power tool 104. In block 1505, the wirelesscommunication controller 250 determines whether the battery packinterface 222 is connected to a battery pack, such as the battery pack104 b (FIG. 1). For example, the processor 258 of the wirelesscommunication controller 250 (FIG. 6B) may monitor an input pin coupledto the power input unit 224 (FIG. 6A) to determine whether power isbeing received from the power input unit 224. Returning to FIG. 15, whenthe wireless communication controller 250 determines that a battery packis coupled to the battery pack interface 222, the wireless communicationcontroller enters the connectable state (block 1510). In block 1515, thewireless communication controller 250 forms a wireless communicationlink with the external device 108. As noted above, the wirelesscommunication link may be the Bluetooth® link or another wirelessprotocol link. The communication link may be particularly formed betweenthe processor 258 of the wireless communication controller 250 and theprocessor 114 of the external device 108 via the antenna and transceiver254 and the short-range transceiver 118. In block 1520, the wirelesscommunication controller 250 communicates, over the wirelesscommunication link, to one or more of transmit tool operational data andreceive tool configuration data from the external device 108. Forexample, in some instances, the wireless communication controller 250transmits tool operational data, such as tool usage data, maintenancedata, mode information, drive device information, and the like from thepower tool 104. Further, in some instances, the wireless communicationcontroller 250 receives tool configuration data, such as operationthresholds (e.g., speed and torque levels), maintenance thresholds, modeconfigurations, programming for the power tool 104, feature information,and the like.

After communicating in block 1520, the wireless communication controller250 returns to block 1505 to determine whether a battery pack isconnected to the battery pack interface 222. When the wirelesscommunication controller 250 determines that no battery pack isconnected to the battery pack interface 222 (e.g., the previouslyconnected battery pack has been disconnected from the battery packinterface 222), the wireless communication controller 250 proceeds toenter the advertisement state (block 1525). In the advertisement state,the wireless communication controller 250 receives power from and ispowered by the backup power source 252. In block 1530, the wirelesscommunication controller 250 transmits an advertisement messageincluding a unique tool identifier. For example, the wirelesscommunication controller 250 may periodically broadcast identificationinformation when in the advertisement state. In some embodiments, thewireless communication controller 250 may respond to requests (e.g.,pings) for identification information. In some embodiments, theadvertisement message includes additional information, such as a chargelevel of the backup power source 252.

In some embodiments, the method 1500 further includes detectingactivation of an actuator, such as by the controller 226 detectingdepression of the trigger 212. In response, in the connectable state,the controller 226 controls the switching network 216 to apply powerfrom the battery pack coupled to the battery pack interface 222 to drivethe motor 214 based on the actuator activation.

In some embodiments, the method 1500 further includes the controller 226obtaining tool usage data from one or more of the sensors 218 while inthe connectable state. Further, the wireless communication controller250 receives the tool usage data from a memory of the power tool (e.g.,over the communication channel 262). The wireless communicationcontroller 250 transmits the tool usage data to the external device aspart of the tool operational data.

In some embodiments, the method 1500 further includes the controller226, while in the connectable state, storing tool configuration datareceived from the external device 108 to the memory 232 (e.g., over thecommunication channel 262). Further, the controller 226 controllingdrives the motor 214 of the power tool based on the tool configurationdata. For example, the controller 226 may drive the motor 214 at a speedspecified in the tool configuration data, or until a torque levelspecified in the configuration data is reached.

In some embodiments, the controller 226 drives the motor 214 when thewireless communication controller 250 is in the connectable state; butthe controller 226 is maintained unpowered when the wirelesscommunication controller 250 is in the advertisement state. For example,as noted, in the advertisement state, the battery pack interface 222 isnot connected to a battery pack. Accordingly, the controller 226 doesnot receive power from the battery pack interface 222 or power inputunit 224. Further, the backup power source 252 is not coupled to thecontroller 226 and does not provide power to the controller 226 in theadvertisement state. Accordingly, the controller 226 remains unpoweredwhen the wireless communication controller 250 is in the advertisementstate.

In some embodiments, the method 1500 further includes the coin cell slot328 (a backup battery receptacle of the power tool) receiving the backuppower source 252. Further, a battery pack, when connected to the batterypack interface 222, blocks the coin cell slot 328 and, whendisconnected, provides access to the coin cell slot 328. For example, asshown in FIG. 5, the coin cell slot 328 is located in the battery packreceiving portion 206. When a battery pack (e.g., the battery pack 104b) is coupled to the battery pack receiving portion 206 (and, thereby,the battery pack interface 222), the coin cell slot 328 is inaccessible.However, when the battery pack is disconnected from the battery packreceiving portion 206, the coin cell slot 328 is again

In some embodiments, the method 1500 further includes powering thewireless communication controller 250 with power from the backup powersource 252 in the advertisement state; and powering the wirelesscommunication controller with power from the backup pack in theconnectable state.

In some embodiments, the method 1500, or a method of displaying acommunication state of a power tool, includes receiving, by the externaldevice 108, data transmitted by the wireless communication controller250. The received data may that which is transmitted in block 1520 andblock 1530 (e.g., one or more of unique tool identifier, anadvertisement message, and operational data). The external device 108determines a communication state of the wireless communicationcontroller. For example, the external device 108 determines whether thewireless communication controller 250 is in the advertisement state orthe connectable state. The determination may be made based on, forexample, a format of the data received from the wireless communicationcontroller 250 or based on state information explicitly included withinthe data received. Upon determining the state of the wirelesscommunication controller 250, the external device 108 displays anindication of the determined state along with an identity of the powertool, which also may be determined based on the received data (e.g.,based on a received unique tool identifier). For example, with referenceto FIG. 8, the external device 108 may display an indication of the toolidentity based on the received data (e.g., based on a unique toolidentifier) along with a wireless symbol in a first style that is grayedout or lighter when in the advertisement state and in a second stylethat is darker or bolder when in the connectable state.

Although the flow charts of FIGS. 7, 14, and 15 are illustrated anddescribed as blocks performed in a serial manner, one or more blocks ofthe methods 700, 1400, and 1500 may be executed in parallel or in adifferent order than described.

In some embodiments, the wireless communication controller 250 remainsin the connectable state even after removal of a battery pack from thebattery pack interface 222. For example, the backup power source 252 maypower the wireless communication controller 250 and the controller 226,enabling both retrieval of tool operational data from the memory 232 forexport to the external device 108 and updating of tool configurationdata residing in the memory 232 based on data received from the externaldevice 108. When the wireless communication controller 250 is in aconnectable state and is powered by the backup power source 252, and abattery pack is not coupled to the battery pack interface 222, the powertool 104 may be referred to as being in a low-power connectable state.In the low-power connectable state, the power tool 104 is operable tocommunicate with the external device 104, as is usual in the connectablestate, but the motor 214 is in a non-drivable state because the powersource for the motor 214 has been removed (i.e., insufficient power isavailable for supply to the switching network 216). The low-powerconnectable state may also be referred to as a non-driving connectablestate, as the motor 214 is not driven, yet full communicationcapabilities are present (i.e., the communications are not limited orrestricted as in the advertisement state). In these embodiments, when abattery pack is coupled to the battery pack interface 222, the powertool 104 enters the previously described, full-power connectable state,such as described with respect to blocks 1510, 1515, and 1520 in FIG.15. This connectable state may also referred to as a driving connectablestate because the motor 214 may be driven and full communicationcapabilities are present.

Thus, the invention provides, among other things, a power tool that canidentify itself to an external device even when a battery pack is notattached to the power tool, and a power tool that can enable atime-based security feature. Various features and advantages of theinvention are set forth in the following claims.

What is claimed is:
 1. A power tool comprising: a battery pack interfacethat selectively receives a battery pack; a wireless communicationcontroller coupled to the battery pack interface and including awireless transceiver and a processor, wherein the wireless communicationcontroller is configured to determine that the battery pack interface isdisconnected from the battery pack; enter an advertisement state forwireless communication based on determining that the battery packinterface is disconnected from the battery pack; and transmit anadvertisement message including a unique tool identifier of the powertool when in the advertisement state.
 2. The power tool of claim 1,wherein the wireless communication controller is further configured to:determine that the battery pack interface is connected to the batterypack; form a wireless communication link with an external device; andcommunicate, over the wireless communication link, to one or more oftransmit tool operational data and receive tool configuration data fromthe external device.
 3. The power tool of claim 1, further comprising: areal-time clock configured to maintain a current time and receive powerfrom a backup power source; wherein the wireless communicationcontroller receives a lock out time from an external device and thepower tool is configured to lock upon the current time exceeding thelock out time.
 4. The power tool of claim 1, further comprising: amotor; a backup power source; a real-time clock coupled to the backuppower source and configured to maintain a current time; a switchingnetwork coupled between the motor and the battery pack interface; anactuator; a controller coupled to the actuator and the switchingnetwork, the controller configured to control the switching network toapply power from the battery pack to drive the motor based on activationof the actuator, wherein the controller is unpowered when the batterypack is disconnected from the battery pack interface; wherein thewireless communication controller is configured to receive a lock outtime; wherein the controller is configured to receive the lock out timefrom the wireless communication controller and the current time, andfurther configured to lock the power tool upon determining that thecurrent time exceeds the lock out time.
 5. The power tool of claim 4,wherein the wireless communication controller receives the lock out timewhile the battery pack is coupled to the battery pack interface; whereinthe battery pack is decoupled from the battery pack interface after thewireless communication controller receives the lock out time and priorto the current time exceeding the lock out time; wherein at least one ofthe battery pack and a second battery pack is coupled to the batterypack interface after the current time exceeds the lock out time; whereinthe controller is configured to lock the power tool upon determiningthat the at least one of the battery pack and the second battery pack iscoupled to the battery pack interface and that the current time exceedsthe lock out time.
 6. The power tool of claim 1, further comprising: abackup battery receptacle configured to receive a backup power source;wherein the backup battery receptacle is blocked when the battery packis connected to the battery pack interface and accessible when thebattery pack is disconnected from the battery pack interface.
 7. Thepower tool of claim 1, further comprising: a housing having an uppermain body, a handle, and a battery pack receiving portion including thebattery pack interface and a backup battery receptacle, wherein theupper main body includes a motor and the handle is connected to theupper main body and to the battery pack receiving portion; and a backuppower source located in the backup battery receptacle.
 8. The power toolof claim 1, wherein the wireless communication controller is furtherconfigured to enter a connectable state for wireless communication by:forming a wireless communication link with an external device; andcommunicating over the wireless communication link to one or more oftransmit tool operational data to the external device and receive toolconfiguration data from the external device; wherein a user interface ofthe external device displays an icon that indicates that the wirelesscommunication controller is in the connectable state.
 9. A power toolcomprising: a battery pack interface that selectively receives a batterypack; a backup power source; and a wireless communication controllercoupled to the backup power source and the battery pack interface, thewireless communication controller including a wireless transceiver and aprocessor, the wireless communication controller configured to  operatein an advertisement state when the wireless communication controller iscoupled to and powered by the backup power source, wherein, in theadvertisement state, the wireless communication controller is configuredto transmit an advertisement message including a charge level of thebackup power source,  wherein transmitting of the advertisement messagein the advertisement state includes periodic broadcasting of theadvertisement message.
 10. The power tool of claim 9, wherein theadvertisement message further includes a unique tool identifier of thepower tool.
 11. The power tool of claim 9, wherein the wirelesscommunication controller is further configured to: determine that thebattery pack interface is connected to the battery pack; form a wirelesscommunication link with an external device; and communicate, over thewireless communication link, to one or more of transmit tool operationaldata and receive tool configuration data from the external device. 12.The power tool of claim 9, further comprising: a real-time clockconfigured to maintain a current time and receive power from the backuppower source; wherein the wireless communication controller receives alock out time from an external device and the power tool is configuredto lock upon the current time exceeding the lock out time.
 13. The powertool of claim 9, further comprising: a motor; a real-time clock coupledto the backup power source and configured to maintain a current time; aswitching network coupled between the motor and the battery packinterface; an actuator; a controller coupled to the actuator and theswitching network, the controller configured to control the switchingnetwork to apply power from the battery pack to drive the motor based onactivation of the actuator, wherein the controller is unpowered when thebattery pack is disconnected from the battery pack interface; whereinthe wireless communication controller is configured to receive a lockout time; wherein the controller is configured to receive the lock outtime from the wireless communication controller and the current time,and further configured to lock the power tool upon determining that thecurrent time exceeds the lock out time.
 14. The power tool of claim 9,further comprising: a backup battery receptacle configured to receivethe backup power source; wherein the backup battery receptacle isblocked when the battery pack is connected to the battery pack interfaceand accessible when the battery pack is disconnected from the batterypack interface.
 15. The power tool of claim 9, further comprising: ahousing having an upper main body, a handle, and a battery packreceiving portion including the battery pack interface and a backupbattery receptacle, wherein the upper main body includes a motor and thehandle is connected to the upper main body and to the battery packreceiving portion; wherein the backup power source is located in thebackup battery receptacle.
 16. The power tool of claim 9, wherein thewireless communication controller is further configured to enter aconnectable state for wireless communication by: forming a wirelesscommunication link with an external device; and communicating over thewireless communication link to one or more of transmit tool operationaldata to the external device and receive tool configuration data from theexternal device; wherein a user interface of the external devicedisplays an icon that indicates that the wireless communicationcontroller is in the connectable state.
 17. A power tool comprising: ahousing having an upper main body, a handle, and a battery packreceiving portion; wherein the upper main body includes a motor and thehandle is connected to the upper main body and to the battery packreceiving portion; wherein the battery pack receiving portion includes abattery pack interface that selectively receives a battery pack, and abackup battery receptacle; a backup power source located in the backupbattery receptacle; and a wireless communication controller coupled tothe backup power source, the wireless communication controller includinga wireless transceiver, a processor, and a unique tool identifier, thewireless communication controller configured to operate in anadvertisement state when the wireless communication controller iscoupled to and powered by the backup power source.
 18. The power tool ofclaim 17, wherein, in the advertisement state, the wirelesscommunication controller is configured to transmit an advertisementmessage including the unique tool identifier; wherein the wirelesscommunication controller is configured to receive power from the batterypack when the battery pack is coupled to the battery pack interface. 19.The power tool of claim 17, wherein the backup battery receptacle isblocked when the battery pack is connected to the battery pack interfaceand accessible when the battery pack is disconnected from the batterypack interface.
 20. The power tool of claim 17, further comprising: areal-time clock configured to maintain a current time and receive powerfrom the backup power source; wherein the wireless communicationcontroller is located in the backup battery receptacle and receives alock out time from an external device; wherein the power tool isconfigured to lock upon the current time exceeding the lock out time.21. The power tool of claim 17, wherein the wireless communicationcontroller is located in the battery pack receiving portion.